VASMIN

Associates

CASE STUDIES INDUCTION

HARDENING
By
V.K.SOOD
Managing Partner
09871090015
 VASMIN
Associates

PROCESS OF INDUCTUCTION HARDENING

-Hardening uses heat and rapid cooling (quenching) to increase the hardness, strength
and/or durability of steel.
-Heating steel or iron above their upper critical temperatures modifies the crystal
structure of the metal to a form called Austenite. With this atomic arrangement the
carbon can then freely migrate to a new location.
-When hardening, the aim is to quickly quench the Austenite, thus trapping the carbon
atoms in their new positions in the crystalline structure.
-The transformed structure, called Marten site, is extremely hard.
-Such hardening creates important internal residual stresses that can be either beneficial
or disadvantageous. Depending on requirements
-Tempering can be carried out after the induction hardening process.
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Multy frequency Induction heating

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Multi Frequency hardening

Contour hardened gears. Variety of induction hardening patterns

obtained
using variations in frequency, heat time,
and coil power.
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Advantages of Induction hardening process

-High throughput
-Shorter leadtimes
-Minimal environmental impact
-Complete control
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Hardening of Steel Cam Assembly

Objective - To harden the perimeter of ¼” thick steel cam assemblies
Material - ¼” thick steel cam assemblies of varying geometries
Temperature - 1650 ºF (900 °C)
Frequency - 177 kHz
Equipment - 5 kW, induction heating system, equipped and an induction heating coil
designed and developed specifically for this application
Process - A two-turn helical coil is used to heat the cams. The heat time varies from
120-150 seconds. After heating, the parts are quenched in water.
Results/Benefits Hardening the cam outer surfaces with induction results in:
• uniform heating for uniform results
• one coil can be used for many geometries
• consistent results from piece to piece
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Roofing screw in coil

hardening a 2” zone

Hardening steel screw threads

Objective Heat steel roofing screw to 1650 ºF to harden the threads
Material Steel roofing screws of varying diameters less than 1.25”
(31.75mm) diameter, 5” (127mm) long
Temperature 1650 ºF (899 ºC)
Frequency 291 kHz
Equipment 2 kW induction heating system.
Process A five turn helical coil is used heat the screw threads. The screw is placed in the
coil, heat is applied for 8 seconds to achieve a 2” long zone at the required hardness.
Results/Benefits Induction heating provides:
• Very rapid heating, faster production rates, efficient
• Ability to incorporate into existing production lines
• Repeatable, consistent results
• Even distribution of heating
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Steel hand held stamp heating

in coil for hardening process

Hardening the end of steel hand-held marking stamps

Objective To harden various size ends of hand held marking stamps. The area to be hardened
is 3/4” (19mm) up the shank.
Material Steel stamps 1/4” (6.3mm), 3/8” (9.5mm), 1/2” (12.7mm) and 5/8” (15.8mm) square
Temperature 1550 ºF (843 ºC)
Frequency 99 kHz
Equipment 30 kW induction heating system.
Process A two turn channel coil is used to cover the range of steel stamps being heated. The
5/8” steel stamp is heated for 60 seconds to reach 1550 ºF (843 ºC) and the desired hardness.
Smaller parts will also heat easily.
Results/Benefits Induction heating provides:
• Faster process time and production rates
• Hands-free heating that involves no operator skill for manufacturing
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Screws heating in coil

Surface hardening of steel screws

Objective Rapid surface hardening of steel screws
Material Steel screws .25” (6.3mm) diameter
Temperature 932 ºF (500 ºC)
Frequency 344 kHz
Equipment 10 kW induction heating system, • An induction heating coil designed and
developed for this application.
Process A three turn channel coil is used to heat 9 screws at a time.Power is applied for 3
seconds to reach 932 ºF (500 ºC) and achieve the required hardness. The screws
travel through the coil head down in an automated system at a rate of 200
screws per minute
Results/Benefits Induction heating provides:
• Precise application of heat
• Faster process time and production rates
• Ability to incorporate into existing production lines
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Case Hardening of Armature Shaft

Objective Harden the gear end of an armature shaft to
58-65 Rockwell C at a depth of 0.02"(.51mm) on the
center line of the teeth and to 49-55 Rockwell C at a
depth of .010" (.3mm) on the center line of the root.
Material Steel armature shaft measuring 7" (177.8mm) in
length with a gear diameter of approximately 1/2"
(12.7mm).
Temperature 1700ºF(926.7ºC)
Frequency 140 kHz
Equipment 20 kW induction heating system.
Process A five turn helical coil is used to heat the gear
end of the shaft to 1700ºF (926.7ºC) for 2.5 seconds to
achieve the desired hardness.
Results/Benefits Induction Heating Provides:
• Pin-point accuracy
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Hardening surgical blades

Objective To quickly heat a steel surgical blade to 2000°F (1093°C)
within 2 seconds so as to harden the blade edge.
Material Stainless steel surgical blades, temperature sensing paint
Temperature 2000°F (1093°C)
Frequency 339kHz
Equipment 3kW induction heating system.
Process A four turn helical coil is used to harden the blades. The induction coil is designed
to provide uniform heat to the entire length of the blade surface. RF power is applied to
heat the entire assembly. The blade reaches the necessary temperature for hardening in 1.2
seconds.
Results/Benefits Induction heating provides:
• Does not affect core structure
• Targeted and rapid heat treating
• Fast, accurate repeatable heat
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Hardening Seat Belt Parts

Objective Heat the teeth of a soft steel seatbelt retraction gear to 1700°F (926.7ºC) within
two seconds for hardening.
Material #4130 steel seatbelt retraction gears, water vortex quenching tank, electronically
controlled air valves, adjustable timers
Temperature 1700 °F(926.7ºC)
Frequency 165 kHz
Equipment 7.5kW induction heating system.
• An induction heating coil designed and developed specifically for this application.
Process A four-turn helical concentrating coil is specially designed to deliver uniform heat to
the steel seatbelt retraction gear. The parts are positioned in the coil above the quenching
tank and held in place with a vacuum rosette fixture. Power is applied for two seconds to
heat the part. The parts are then expelled into the quench tank for cooling.
Results/Benefits Induction heating provides:
• Uniform and repeatable results
• Energy efficient
• Non-contact heating
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“YOUR GROWTH PARTNER THRU

VALUE ADDED SERVICES TO
MANUFACTURING INDUSTRIES
ASSOCIATES”

V.K.SOOD
Managing Partner
VASMIN Associates
27, Shankar market, Connaught circus
New Delhi 110 001, India
Cell no +91-9871090015 Phone +91-11-30422704
[email protected]